Engine air intake device

ABSTRACT

A cover covering an engine and an intake duct for introducing fresh air outside an engine room into a combustion chamber of the engine are provided in the engine room. The cover includes a top face cover portion covering the engine from above, and a side face cover portion covering the engine from the lateral side. The intake duct is disposed so as to be continuous to a side edge of the side face cover portion such that the intake duct covers the engine from the lateral side together with the side face cover portion.

TECHNICAL FIELD

The present invention relates to an intake device for an engine.

BACKGROUND ART

It has been conventionally known that, in an engine room of a vehicle,an engine is covered with a cover member to keep the engine warm. Forexample, Patent Literature 1 discloses providing, in an engine room, acylinder head-side thermal insulating cover composed of an upper wallcovering a top face of an engine and a side wall covering both sidefaces of an upper portion of the engine in the vehicle width direction.The vehicle front side of the thermal insulating cover is supported onan upper end of a radiator shroud, and the vehicle rear side thereof issupported on a dash panel. Furthermore, Patent Literature 1 alsodiscloses providing a cylinder block-side thermal insulating covercovering a face on the vehicle front side of a cylinder block, a face onthe vehicle rear side of the cylinder block, both side faces of thecylinder block in the vehicle width direction, and substantially theentire oil pan.

CITATION LIST Patent Literature

Patent Literature 1: Japanese Patent Laid-Open No. 2017-180210

SUMMARY OF INVENTION Technical Problem

In a case where a cover member covering an engine is provided in anengine room, the layout of an intake duct leading fresh air to acombustion chamber of the engine becomes a problem. Normally, it isconceivable that an air cleaner is protruded outside the cover memberand that the intake duct is disposed outside the cover member andconnected to the air cleaner. is recognized that Patent Literature 1also adopts such a configuration. However, since the intake duct isdisposed apart from the engine toward the outside of the cover member,it is difficult to secure a disposition space of the intake duct in theengine room, and in addition, normally, an intake passage also becomeslong.

Thus, in a case where a cover covering an engine is provided asdescribed above, the present invention suppresses outward spread of aspace to be secured in an engine room for disposition of an intake duct,and also achieves shortening of an intake passage and downsizing of anintake device.

Solution To Problem

To solve the problem, in the present invention, an intake duct forms apart of a cover covering an engine from the lateral side.

An intake device for an engine disclosed herein has a cover providedinside an engine room and covering the engine, and an intake duct forintroducing fresh air outside the engine room into a combustion chamberof the engine, wherein:

-   -   the cover includes a top face cover portion covering the engine        from above, and a side face cover portion covering the engine        from the lateral side, and    -   the intake device is characterized in that    -   the intake duct is disposed so as to be continuous to a side        edge of the side face cover portion such that the intake duct        covers the engine from the lateral side together with the side        face cover portion.

According to this, the intake duct is continuous to the side edge of tieside face cover portion, so that the intake duct. approaches the engineas compared with a case where the intake duct is disposed outside theside face cover portion. This prevents an increase in a space occupiedby, in the engine room, the cover and air intake system componentsincluding the intake duct, facilitating the layouts of the cover and theair intake system components in the engine room.

Furthermore, the intake duct can be caused to approach the engine, sothat an intake passage is prevented from becoming long. The intake ducthas a function of covering the engine from the lateral side so that theside face cover portion can be made small accordingly. By the shorteningof the intake passage and the downsizing of the side face cover portionas described above, the device is advantageously reduced in weight.

In an embodiment, the engine room is provided in a front portion of avehicle,

-   -   the engine is a front intake and rear exhaust engine, and    -   the intake duct is disposed so as to be continuous to a side        edge on the front side of the side face cover portion.

In the front intake-type engine, the intake duct is disposed on thefront side of the side face cover portion, so that it is advantageous inshortening the intake passage.

In an embodiment, the intake duct and the side face cover portion arecoupled together by a fastening member. Thus, the intake duct can beused for support of the side face cover portion, which is advantageousin reducing the number of components and enhancing mounting stability ofthe side face cover portion.

In an embodiment, the fastening member is a clip having a retainer.Accordingly, coupling of the side face cover portion and the intake ductis facilitated.

Advantageous Effect of Invention

According to the present invention, in a case where the cover includingthe top face cover portion covering the engine from above and the sideface cover portion covering the engine from the lateral side areprovided in the engine room, the intake duct is disposed so as to becontinuous to the side edge of the side face cover portion such that theintake duct covers the engine from the lateral side together with theside face cover portion, so that the layouts of the cover and the airintake system components in the engine room are facilitated, theshortening of the intake passage is achieved, and in addition, thedevice is advantageously reduced in weight.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a right side view illustrating a state in which, inside anengine room including an intake device according to an embodiment of thepresent invention, an engine is covered with a heat storage cover.

FIG. 2 is a plan view illustrating a state in which the engine iscovered with the heat storage cover (note that a top face cover portionis indicated by the chain line to represent an inside of the cover).

FIG. 3 is a front view illustrating a state in which the engine iscovered with the heat storage cover.

FIG. 4 is a left side view illustrating a state in which the engine iscovered with the heat storage cover.

FIG. 5 is a perspective view illustrating an intake duct, an aircleaner, and the heat storage cover.

FIG. 6 is a perspective view similar to FIG. 5 which is illustrated in astate in which the top face cover portion of the heat storage cover isexcluded.

FIG. 7 is a right side view illustrating the top face cover portion ofthe heat storage cover, a right-side face cover portion of the heatstorage cover, and the intake duct.

FIG. 8 is a perspective view illustrating a relationship between theintake duct and the right-side face cover, as viewed from the inside ofthe cover.

FIG. 9 is a perspective view illustrating the intake duct, as viewedfrom the diagonally right front side.

FIG. 10 is a perspective view illustrating the intake duct, as viewedfrom the diagonally left rear side.

FIG. 11 is a plan view of the intake duct.

FIG. 12 is a cross-sectional view taken along line XII-XII of FIG. 11.

FIG. 13 is an exploded perspective view of the intake duct.

FIG. 14 is a perspective view illustrating a second duct member of theintake duct in a state in which a passage switching mechanism isexcluded.

FIG. 15 is an exploded perspective view of the passage switchingmechanism.

FIG. 16 is a perspective view illustrating the passage switchingmechanism in an assembled state.

FIG. 17 is a front view illustrating a part of the assembled state ofthe passage switching mechanism.

FIG. 18 is a perspective view illustrating a state in which the passageswitching mechanism is assembled to the intake device.

DESCRIPTION OF EMBODIMENTS

Hereinafter, a mode for carrying out the present invention will bedescribed based on the drawings. The following description of apreferred embodiment is merely illustrative in nature and is notintended to limit the present invention, applications thereof, or usethereof.

<Configurations of Engine and Peripherals>

FIG. 1 illustrates an inside of an engine room 1 including an intakedevice for an engine according to the present embodiment. The engineroom 1 is provided as a recessed opening on the upper side in a vehiclefront portion and accommodates an engine 2 and peripherals of the engine2. The opening on the upper side of the engine room 1 is blocked by abonnet 3. The bonnet 2 is openable and closable, so that the inside ofthe engine room 1 can be seen from the outside of a vehicle by openingthe bonnet 3 as necessary.

Here, “the inside of the engine room 1” refers to a space defined whenthe opening on the upper side of the engine room 1 is blocked by closingthe bonnet 3. In the present description, the advancing-recedingdirection of the vehicle is referred to as “the front-rear direction,”the advancing side is referred to as “the front side,” and the recedingside is referred to as “the rear side.” Furthermore, the vehicle widthdirection is referred to as “the left-right direction.” Furthermore,“the right side” and “the left side” are when the vehicle is viewed fromthe front side.

The engine 2 includes a cylinder block 4 and a cylinder head placed onthe cylinder block 4. An oil pan 5 is fixed to a bottom face of thecylinder block 4. Although not illustrated, a plurality of cylinders areformed inside the cylinder block 4. That is, the engine 2 is amulti-cylinder engine. A piston is slidably inserted into each cylinder.The piston is connected to a crankshaft via a connecting rod. The pistondefines a combustion chamber of the engine 2 together with the cylinderand the cylinder head.

Fresh air is introduced into the combustion chamber of the engine 2through an intake duct 11 and an air cleaner 12. The air cleaner 12 is adevice that removes foreign matter such as dust or dirt contained in thefresh air to be introduced into the combustion chamber.

FIG. 2 is a view of the engine 2 as viewed from the top, with a top facecover 22 of a heat storage cover 21, which will be described later,being removed.

As illustrated in the same figure, the fresh air passes through anintake pipe 13 including a throttle valve from the air cleaner 12 and isintroduced into a supercharger 14. The supercharger 14 increases thepressure of the fresh air to be introduced into the combustion chamber.The supercharger 14 of the present example is a mechanical superchargerthat is driven via a belt by the crankshaft of the engine 2. Note thatan electric supercharger or a turbocharger that is driven by exhaustenergy may be adopted. The fresh air passing through the supercharger 14is cooled by an intercooler 15 illustrated in FIG. 3 and is introducedinto the combustion chamber of each cylinder via a surge tank and anintake manifold.

As illustrated in FIG. 2, a bypass pipe 16 bypassing the supercharger 14and leading the fresh air to the surge tank branches from the intakepipe 13. The bypass pipe 16 is provided with a bypass valve that adjustsan opening area of a conduit of the bypass pipe 16. An EGR pipe 17illustrated in FIG. 1 is connected to a section upstream of the bypassvalve of the bypass pipe 16. The EGR pipe 17 returns, as EGR gas, aportion of exhaust gas to the combustion chamber and includes an EGRcooler 18 that cools the EGR gas.

The intake duct 11, the air cleaner 12, the intake pipe 13, thesupercharger 14, the intercooler 15, the surge tank, and the intakemanifold which form an air intake system of the engine 2 are disposed onthe front side of the engine 2, and an exhaust manifold and an exhaustpipe continuing to the exhaust manifold which form an exhaust system ofthe engine 2 are disposed on the rear side of the engine 2. That is, theengine 2 is a front intake and rear exhaust engine.

<Cover Structure of Engine>

The heat storage cover 21 is provided in the engine room 1, covers theengine 2 from above the engine 2, and surrounds the periphery of anupper portion of the engine 2. Heat dissipated from the engine 2 isstored inside the heat storage cover 21 through the medium of air, andthe heat storage cover 21 blocks at least a part of upward heatdissipation.

Here, “the inside of the heat storage cover” refers to the lower sideof, in the heat storage cover, an inner face of a portion covering theengine from above, and the inside of, in the heat storage cover, aninner face of a portion at least partially surrounding the periphery ofthe engine.

The heat storage cover 21 includes, as illustrated in FIG. 1, the topface cover portion 22 covering the engine 2 from above, a rear facecover portion 23 continuous to the top face cover portion 22 andcovering the upper portion of the engine 2 from behind, and a right-sideface cover portion 24 continuous to the top face cover portion 22 andcovering the upper portion of the engine 2 from the right side, andfurther includes, as illustrated in FIG. 4, a left-side face coverportion 25 continuous to the top face cover portion 22 and covering theupper portion of the engine 2 from the left side.

A radiator 6 that cools cooling water of the engine 2 by heat exchangewith air is disposed in front of the engine 2 so as to cover the engine2 from the front side. A grille shutter 7 capable of blockingventilation from the front side to the radiator 6 is provided in frontof the radiator 6. The radiator 6 includes, on the back side, a radiatorfan 8 that dissipates heat of the cooling water toward the engine 2. Afront grille 9 is provided in front of the grille shutter 7.

The grille shutter 7 has a plurality of flaps 26 disposed at intervalsin the up-down direction and includes an actuator that pivots each ofthe plurality of flaps 26. When the flaps 26 become horizontal asindicated by the chain line, ventilation from the front side to theradiator 6 is allowed, and when the flaps 26 become vertical asindicated by the solid line, the ventilation to the radiator 6 isblocked. When a passage switching mechanism of the intake duct 11, whichwill be described later, is operated and introduction of the fresh airinto the combustion chamber of the engine 2 is brought into an insideair introduction state, in the grille shutter 7, the flaps 26 becomevertical, thereby suppressing collision of vehicle traveling air againstthe radiator 6. As a result, heat dissipation from the engine room 1 tothe front side is also suppressed.

Cooling water inflow hoses 27 and 28 (see FIGS. 2 and 4) through whichthe cooling water from the engine 2 flows in, and a cooling wateroutflow hose 31 (see FIGS. 1 and 2) through which cooling water whosetemperature has decreased is sent to a water pump 29 illustrated in FIG.4 are connected to the radiator 6.

Here, the heat storage cover 21 blocks heat dissipation from the upperportion of the engine 2 to the upper side and the periphery, therebycontributing to keeping the engine 2 warm. On the other hand, theradiator 6 and the grille shutter 7 block heat dissipation from theengine 2 to the front side, thereby contributing to keeping the engine 2warm. Furthermore, the radiator 6 emits the heat of the cooling watertoward the engine 2 by using the radiator fan 8, thereby making heatstorage of the heat storage cover 21 advantageous.

(Details of Heat Storage Cover)

As illustrated in FIG. 5, the air cleaner 12 is disposed on the rightouter side of the heat storage cover 21 as viewed from the vehicle frontside. The intake duct 11 is disposed on the outside of the heat storagecover 21 and on the front side of the air cleaner 12.

As illustrated in FIGS. 1, 4, and 5, the top face cover portion 22 ofthe heat storage cover 21 includes an upper wall 22 a gradually inclineddownward toward the front side, and upper side walls 22 b and 22 c (seeFIGS. 1 and 4) continuing to both side edges of the upper wall 22 a andextending downward. The upper wall 22 a spreads outward relative to atop face of the engine 2 so as to cover the entire top face of theengine 2. A front end portion of the upper wall 22 a is provided with afixed portion 22 d for fixing the heat storage cover 21 to a radiatorshroud 20.

As illustrated in FIGS. 1, 4, and 6, the rear face cover portion 23 ofthe heat storage cover 21 includes a rear wall 23 a spread in theleft-right direction so as to cover a rear face of the upper portion ofthe engine 2, and rear side walls 23 b and 23 c continuing to respectiveside edges of the rear wall 23 a and extending forward. The rear wall 23a includes a bracket 23 d protruding rearward for fixing the heatstorage cover 21 to a cowl panel of the vehicle. As illustrated in FIG.6, an upper end of the rear wall 23 a and front end upper portions ofthe rear side walls 23 b and 23 c are each provided with a seal 32 forpreventing a gap with respect to the top face cover portion 22 fromoccurring. That is, a rear end edge of each of the upper wall 22 a andthe upper side wall 22 b in the top face cover portion 22 abuts againstthe seal 32.

As illustrated in FIGS. 1 and 7, the right-side face cover portion 24 ofthe heat storage cover 21 spreads in the front-rear direction so as tocover the upper portion of the engine 2 from the right side togetherwith a right-side rear side wall of the rear face cover portion 23. Afront end edge of the right-side face cover portion 24 abuts against aprotrusion 33 (see FIGS. 7 and 10) protruding rearward relative to theintake duct 11 and extending in the up-down direction. As illustrated inFIGS. 6 to 8, a mounting piece 34 protruding forward relative to anupper end of the front end edge of the right-side face cover portion 24is fixed to a mounting portion 33 a of an upper end of the protrusion 33of the intake duct 11 by a clip 35 having a retaining function as afastening member. A rear end edge of the right-side face cover portion24 abuts against a front end lower portion of the right-side rear sidewall 23 b of the rear face cover portion 23.

Here, as illustrated in FIG. 7, the intake duct 11 is provided with anoutside air inlet 44, which will be described later, at substantiallythe same height as an upper edge of the right-side face cover portion24, and is, when the whole of the duct is viewed from the lateral side,formed so as to include an upper portion 11 a substantially horizontallyextending rearward from the outside air introduction port 44, anintermediate portion 11 b continuing to the upper portion 11 a andextending downward, and a lower portion 11 c continuing to theintermediate portion 11 b, extending rearward, and connected to the aircleaner 12. As illustrated in FIG. 8, the protrusion 33 of the intakeduct 11 passes through the intermediate portion 11 b from a rear end ofthe upper portion 11 a of the intake duct 11 and extends in the up-downdirection up to the lower portion 11 c, and as illustrated in FIG. 7,this protrusion 33 is connected to a side edge on the front side of theright-side face cover portion 24. That is, the intake duct 11 iscontinuous to the side edge on the front side of the right-side facecover portion 24. Accordingly, the intake duct 11 functions as a covermember covering the upper portion of the engine 2 from the right sidetogether with the right-side face cover portion 24.

As illustrated in FIG. 7, the right-side upper side wall 22 b of the topface cover portion 22 is placed on the upper edge of the right-side facecover portion 24 via a seal 36. At a lower edge of the right-side upperside wall 22 b of the top face cover portion 22 and the upper edge ofthe right-side face cover portion 24, semi-circular cutouts 22 e and 24a are formed which are opposed in the up-down direction and throughwhich a flexible pipe 37 extending toward the engine 2 from the aircleaner 12 illustrated in FIGS. 6 and 8 passes. The flexible pipe 37 isconnected to the intake pipe 13 described earlier.

As illustrated in FIGS. 4 and 6, the left-side face cover portion 25 ofthe heat storage cover 21 spreads in the front-rear direction so as tocover the upper portion of the engine 2 from the left side together withthe left-side rear side wall 23 c of the rear face cover portion 23 andan engine mount 38. That is, the left-side face cover portion 25 and theleft-side rear side wall 23 c of the rear face cover portion 23 aredisposed on the front and rear sides of the engine mount 38.Accordingly, the engine mount 38 functions as a cover member coveringthe upper portion of the engine 2 from the left side together with theleft-side face cover portion 25. The engine mount 38 has front and rearleg portions 38 a fixed to a front side frame of the vehicle and has anupper portion on which the engine 2 is supported. In the engine mount38, a space between the front and rear leg portions 38 a is blocked fromthe viewpoint of obtaining a cover function.

<Disposition and Structure of Intake Duct>

As illustrated in FIGS. 9 and 10, the intake duct 11 includes an outsideair introduction duct portion 41 for introducing outside air which isair outside the engine room 1 and an inside air introduction ductportion 42 for introducing air inside the engine room 1, and is acomposite duct in which both duct portions 42 and 43 are connected toone downstream duct portion 43.

An upstream end of the outside air introduction duct portion 41 isprovided with the outside air inlet 44 open forward and having ahorizontally long rectangular shape. An upstream end of the inside airintroduction duct portion 42 is provided with an inside air inlet 45open upward and having a horizontally long rectangular shape. At adownstream end of the downstream duct portion 43, a connection port 46connected to the air cleaner 12 is open rearward.

As illustrated in FIG. 11, the intake duct 11 includes mounting pieces47 protruding toward both sides of the upper portion 11 a from the upperportion 11 a extending rearward from the outside air inlet 44 of theoutside air introduction duct portion 41. The downstream end of thedownstream duct portion 43 is provided with a flange 48 for connectingto the air cleaner 2.

In the intake duct 11, the mounting pieces 47 are fixed to a top face ofthe radiator shroud 20 illustrated in FIG. 1. Thus, the outside airinlet 44 of the outside air introduction duct portion 41 is provided soas to face forward from the top of the radiator shroud 20. On the otherhand, as illustrated in FIG. 2, the inside air inlet 45 of the intakeduct 11 is provided between the engine 2 and the radiator 6 so as toface the inside of the heat storage cover 21 from below. Note that theinside air inlet 45 is covered with the outside air introduction ductportion 41 and a projection portion 51, which will be described later,from the top.

(Cover Structure of Inside Air Inlet)

A part of the inside air inlet 45 of the inside air introduction ductportion is covered with the outside air introduction duct portion 41from the top with a gap, and the remaining portion of the inside airinlet 45 is covered with the projection portion 51 from the top with agap. Hereinafter, this cover structure will be described.

As illustrated in FIG. 9, the outside air introduction duct portion 41and the inside air introduction duct portion 42 branch from thedownstream duct portion 43 and rise so as to be arranged in theleft-right direction, and the outside air introduction duct portion 41rises so as to be higher than the inside air inlet 45 of the inside airintroduction duct portion 42.

As illustrated in FIGS. 10 and 11, the outside air introduction ductportion 41, at a higher position than the inside air inlet 45 of theinside air introduction duct portion 42, has a duct wall 41 a curvedtoward the inside air introduction duct portion 42 side and extendingforward diagonally across above the inside air inlet 45 of the insideair introduction duct portion 42. As also illustrated in FIGS. 11 and12, a front-side portion of the inside air inlet 45 of the inside airintroduction duct portion 42 is formed so as to be covered by this ductwall 41 a from above. A portion extending forward from the duct wall 41a of the outside air introduction duct portion 41 forms the upperportion 11 a of the intake duct 11.

The outside air introduction duct portion 41 includes the projectionportion 51 having a collar-like shape and protruding rearward above theinside air inlet 45 of the inside air introduction duct portion 42 froma rear face of the duct wall 41 a. This projection portion 51 covers theremaining portion of the inside air inlet 45 from above. As illustratedin FIG. 10, the projection portion 51 is inclined downward toward arising portion of the outside air introduction duct portion 41, and thisinclined portion covers the inside air inlet 45 from the lateral side,that is, from the diagonally upper side.

From the viewpoint of prevention of entry of foreign matter, it isadvantageous that an interval between the projection portion 51 and theinside air take-in port 45 is as narrow as possible. If it is desired toprevent entry of a bolt during assembly, it is conceivable that, forexample, the interval between the projection portion 51 and the insideair take-in port 45 is set so as to be smaller than the diameter of anM6 nut. Note that if the interval is narrowed excessively, theprojection portion 51 serves as a ventilation resistance and preventsinside air from being brought into the inside air take-in port 45.Accordingly, the interval between the projection portion 51 and theinside air take-in port 45 is preferably set in a range of, for example,10 to 60 mm in comprehensive consideration of these problems. In thepresent embodiment, this interval is 40 mm.

(Passage Switching Mechanism of Intake Duct)

The passage switching mechanism of the intake duct 11 switches theintroduction of the fresh air into the combustion chamber of the engine2 between an outside air introduction state in which outside air outsidethe engine room 1 is introduced into the air cleaner 4 by the outsideair introduction duct portion 41, and the inside air introduction statein which air in the engine room 1, in particular, hot air obtained bythe heat storage cover 21, is introduced into the air cleaner 4 by theinside air introduction duct portion 42. Thus, the passage switchingmechanism includes a first valve 61 and a second valve 62, which will bedescribed later.

As illustrated in FIG. 13, the intake duct 11 is formed by a first ductmember 11A made of synthetic resin and a second duct member 11B made ofsynthetic resin being mated at respective peripheral edge portions andwelded together. In the present example, the first duct member 11A formsa front portion of the intake duct 11 including the outside air inlet 44of the outside air introduction duct portion 41. The second duct member11B forms a rear portion of the intake duct 11 including the connectionport 46 of the downstream duct portion 43. The first duct member 11A andthe second duct member 11B are mated, so that the outside airintroduction duct portion 41, inside air introduction duct portion 42,and downstream duct portion 43 of the intake duct 11 are completed.

As illustrated in FIG. 13, the outside air introduction duct portion 41forms an outside air introduction passage 55, and the inside airintroduction duct 42 forms an inside air introduction passage 56. Theoutside air introduction passage 55 and the inside air introductionpassage 56 continue to a downstream introduction passage 57 formed bythe downstream duct portion 43. The first valve 61 that opens and closesthe outside air introduction passage 55 is disposed in the outside airintroduction duct portion 41, and the second valve 62 that opens andcloses the inside air introduction passage 56 is disposed in the insideair introduction duct portion 42.

As described earlier, the outside air introduction duct portion 41 andthe inside air introduction duct portion 42 branch from the downstreamduct portion 43 and rise so as to be arranged in the left-rightdirection, and the first valve 61 and the second valve 62 are disposedat base ends of the rising of the outside air introduction duct portion41 and the rising of the inside air introduction duct portion 42. Thatis, a first valve disposition portion of the outside air introductionpassage 55 and a second valve disposition portion of the inside airintroduction passage 56 are provided in parallel across a partition wall58 separating both passages 55 and 56.

The first duct member 11A forms a part of the first valve dispositionportion of the outside air introduction passage 55 and a part of thesecond valve disposition portion of the inside air introduction passage56 in respective passage wall circumferential directions, and the secondduct member 11B forms the remaining portions thereof in the passage wallcircumferential directions.

The first valve 61 is a flap-type valve, and the second valve 62 is abutterfly-type valve. That is, both valves 61 and are rotation-typevalves that rotate to open and close the passages, and are supported onone rotation shaft 63 extending over both of the outside airintroduction duct portion 41 and the inside air introduction ductportion 42. Both valves 61 and 62 are positioned at a predeterminedangle with respect to the rotation shaft 63 and supported so that, wheneither one of them is open, the other one is closed.

The rotation shaft 63 is supported on the second duct member 11B formingthe rear portion of the intake duct 11, and an actuator 64 thatrotationally drives the rotation shaft 63 is also supported on thesecond duct member 11B. That is, as illustrated in FIG. 14, the secondduct member 11B is provided with shaft support portions 65 and 66 forallowing the second duct member 11B to solely support the rotation shaft63, and an actuator support portion 67 for allowing the second ductmember 11B to solely support the actuator 64.

In the present example, the shaft support portions 65 and are providedin opposing duct walls on the outside air introduction duct portion 41side and on the inside air introduction duct portion 42 side in thesecond duct member 11B. The actuator support portion 67 is provided onan outside face on the outside air introduction duct portion 41 side inthe second duct member 11B.

As described above, the rotation shaft 63 is supported on the secondduct member 11B, so that the first valve 61 and the second valve 62 arealso supported on the second duct member 11B by the second duct member11B alone.

As illustrated in FIG. 14, the shaft support portion 66 on the insideair introduction duct portion 42 side is provided with a support hole71, and a bush 72 illustrated in FIG. 15 is fitted to the support hole71. Similarly, the shaft support portion 65 on the outside airintroduction duct portion 41 side is provided with a support hole 71(illustration omitted), and a bush 72 illustrated in FIG. 15 is fittedto the support hole 71.

As illustrated in FIG. 15, the rotation shaft 63 is a shaft having asquare shape (rectangular cross-section in the present example) and ispassed through cylindrical fitting portions 73 to 77 provided at shaftportions of the first valve 61 and the second valve 62. The first valve61 is provided with, at two locations on both sides in the axisdirection, the fitting portions 73 and whose end portions protrudeoutward in the axis direction relative to the first valve 61. The secondvalve 62 is provided with, at two locations on both sides in the axisdirection, the fitting portions 75 and 76 whose end portions protrudeoutward in the axis direction relative to the second valve 62, and isprovided with the fitting portion 77 at one intermediate location.

Outer circumferential faces of the fitting portions 73 to 77 in thefirst valve 61 and the second valve 62 are circular, while fitting holesthereof all have a square shape corresponding to the cross-sectionalshape of the rotation shaft 63. The rotation shaft 63 is passed throughthe fitting holes of the fitting portions 73 to 77 of both valves 61 and62, and both valves 61 and 62 are supported so as not to rotate withrespect to the rotation shaft 63.

In a state in which the rotation shaft 63 is passed through the fittingportions 73 to 77 of the valves 61 and 62, the fitting portions 73 and76 at both ends of the fitting portions 73 to 77 are fitted to thebushes 72 of the shaft support portions 65 and 66 and rotatablysupported thereon. In other words, the rotation shaft 63 is rotatablysupported on the bushes 72 of the shaft support portions 65 and 66 viathe fitting portions 73 and 76 of the valves 61 and 62.

Axially opposed end portions of the fitting portion 74 of the firstvalve 61 and the fitting portion 75 of the second valve 62 which areaxially adjacent to each other have a shape cut out in asemi-cylindrical shape, and the cutout portions are engagement portions78 and 79. Both engagement portions 78 and 79 engage with each other inthe valve rotation direction in a state in which the rotation shaft 63is passed through the fitting portions 73 to 77, and regulate a relativeposition between the first valve 61 and the second valve 62 in the valverotation direction.

That is, as illustrated in FIG. 16, when, in a state in which theengagement portions 78 and 79 of both valves 61 and 62 are engaged witheach other, the rotation shaft 63 is passed through the fitting portions73 to 77 of both valves 61 and 62, both valves 61 and 62 are broughtinto a state of being positioned with respect to the rotation shaft 63so that, by rotation of the rotation shaft 63, when either one of themis open, the other one is closed. In the case of the present example,both valves 61 and 62 are positioned in a state in which valve bodiesthereof are shifted by 90 degrees in the rotation direction.

The fitting portion 74 of the first valve 61 and the fitting portion 75of the second valve 62 which are adjacent to each other are respectivelyprovided with projections 82 and 83 protruding laterally for allowing aspacer 81 illustrated in FIG. 15 to regulate positions of both valves 61and 62 in the valve axis direction.

Hereinafter, specific description will be given. As illustrated in FIG.14, in the partition wall 58 of the second duct member 11B, a spacerreceiver 85 is formed which has a recess 84 to which the fittingportions 74 and 75 are rotatably fitted. A fitting groove 86 is formedin this spacer receiver 85. On the other hand, a recess 87 correspondingto the recess 84 of the spacer receiver 85 and a ridge 88 to be fittedto the fitting groove 86 are formed in the spacer 81. The spacer 81 isdimensioned so that the length thereof in the valve axis direction isequivalent to an interval between the projections 82 and 83 when bothvalves 61 and 62 are positioned in normal positions of the outside airintroduction duct portion 41 and the inside air introduction ductportion 42.

In a state in which the first valve 61 and the second valve 62 are setin the second duct member 11B, the ridge 88 is fitted to the fittinggroove 86, so that the spacer 81 is placed in the spacer receiver 85. Atthis time, as illustrated in FIG. 17, the projection 82 on the firstvalve 61 side abuts against one side of the spacer 81, and theprojection 83 on the second valve 62 side abuts against the oppositeside of the spacer 81. The projections 82 and 83 engage with the spacer81 in the valve axis direction, so that, in both valves 61 and 62, thepositions in the valve axis direction are regulated so as not to hinderthe opening and closing.

(Assembly of Intake Duct)

The bush 72 illustrated in FIG. 15 is fitted to the support hole 71 ofeach of the shaft support portions 65 and 66 of the second duct member11B illustrated in FIG. 14.

As illustrated in FIG. 18(a), the first valve 61 is put in the valvedisposition portion (first valve disposition portion) on the outside airintroduction duct portion 41 side of the second duct member 11B. Thefirst valve 61 is moved in the valve axis direction to fit the fittingportion 73 to the bush 72 of the shaft support portion 65.

As illustrated in FIG. 18(b), the first valve 61 is positioned at apredetermined rotation angle. That is, in the present example, the firstvalve 61 rotates so as to abut against a passage wall on the back sideof the outside air introduction duct portion 41.

As illustrated in FIG. 18(c), in a state in which the first valve 61 ispositioned as described above, the second valve 62 is put in the valvedisposition portion (second valve disposition portion) on the inside airintroduction duct portion 42 side of the second duct member 11B. At thistime, the engagement portion 78 of the first valve 61 and the engagementportion 79 of the second valve 62 are engaged. Thus, both valves 61 and62 are brought into a state of being relatively positioned at thepredetermined rotation angle. Then, the second valve 62 is moved in thevalve axis direction to fit the fitting portion 76 to the bush 72 (seeFIG. 15) of the shaft support portion 66.

As illustrated in FIG. 18(d), the spacer 81 is fitted to the spacerreceiver 85, and the projection 82 of the first valve 61 and theprojection 83 of the second valve 62 abut against both side faces of thespacer 81. Thus, the positions of the first valve 61 and the secondvalve 62 in the outside air introduction duct portion 41 and the insideair introduction duct portion 42 in the valve axis direction are broughtinto a state of being regulated to planned positions.

As illustrated in FIG. 18(e), the rotation shaft 63 whose end portionillustrated in FIG. 15 is coupled to a gear 89 is inserted into thefitting portions 73 and 74 of the first valve 61 and the fittingportions 75 to 77 of the second valve 62 from outside the outside airintroduction duct portion 41 via the bush 72 of the shaft supportportion 65. The gear 89 is provided with a stopper 90 illustrated inFIG. 15, and the stopper 90 abuts against the second duct member 11B, sothat the rotation shaft 63 is positioned in the axis direction.

Thereafter, the first duct member 11A and the second duct member 11B arewelded together. Then, mounting of a cap 91 illustrated in FIG. 15, theactuator 64, and a bell mouth 92 is performed. That is, the cap 91 isfitted to the shaft support portion 66 on the inside air introductionduct portion 42 side from outside. A gear coupled to an output shaft ofthe actuator 64 meshes with the gear 89 of the rotation shaft 63, andthe actuator 64 is mounted on the actuator support portion 67 on thesecond duct member 11B side. The bell mouth 92 is fitted to the insideair inlet 45 of the inside air introduction duct portion 42.

Note that the cap 91 and the actuator 61 may be first mounted on thesecond duct member 11B and then the first duct member 11A and the secondduct member 11B may be welded together.

<Advantages of the Embodiment>

(Introduction of Air into Engine Combustion Chamber)

According to the embodiment, the first valve 61 and the second valve 62are operated by the actuator 61 illustrated in FIG. 13, so thatswitching can be made between the outside air introduction state inwhich the outside air introduction passage 55 of the intake duct 11 isopen and the inside air introduction passage 56 is closed, and theinside air introduction state in which the outside air introductionpassage 55 is closed and the inside air introduction passage 56 is open.

In the outside air introduction state, the air outside the engine room 1illustrated in FIG. 1 passes through the outside air introductionpassage 55 illustrated in FIG. 13 and the like from the outside airinlet 44 of the intake duct 11 and enters the air cleaner 12, and theoutside air is introduced into the combustion chamber of the engine 2.In the inside air introduction state, the air inside the engine room 1passes through the inside air introduction passage 56 from the insideair inlet 45 of the intake duct 11 and enters the air cleaner 12, andhigh temperature inside air in the engine room 1 is introduced into thecombustion chamber of the engine 2.

The inside air introduction state will be described. Air around theengine 2 is warmed by the heat dissipated from the engine 2 and rises,and the air enters the inside of the heat storage cover 21. The heatstorage cover 21 blocks the upward (bonnet 3 side) heat dissipation, sothat the heat dissipated from the engine 2 is stored inside the heatstorage cover 21 through the medium of air. As a result, the temperatureof air inside the heat storage cover 21 or below the heat storage cover21 becomes high.

The inside air inlet 45 of the intake duct 11 faces the inside of theheat storage cover 21 from the bottom, so that the high temperature airobtained by the heat storage cover 21 is brought into the inside airintroduction passage 56 of the intake duct 11. Accordingly, the hightemperature air is introduced into the combustion chamber of the engine2 through the air cleaner 12, so that, for example, even when a largeamount of air is required as in a lean combustion, a decrease intemperature of the combustion chamber is suppressed, which isadvantageous in securing combustion stability of the engine 2.

In the embodiment, the radiator 6 illustrated in FIG. 1 serves toprevent heat dissipation from the engine 2 to the front side, and wasteheat released from the radiator 6 (heat taken from the cooling water byheat exchange) is supplied to the engine 2 side by the radiator fan 8.Thus, the temperature of air between the engine 2 and the radiator 6becomes high. Furthermore, an escape of the heat to the rear side andlateral side of the engine 2 is suppressed by the rear face coverportion 23 and the side face cover portions 24 and 25 in the heatstorage cover 21, so that the high temperature air is easily storedbetween the engine 2 and the radiator 6 in front of the engine 2.

Thus, as illustrated in FIG. 2, the inside air inlet 45 is disposedbetween the engine 2 and the radiator 6, so that it is advantageous inincreasing the temperature of the air to be brought into the intake duct11. Furthermore, during the inside air introduction state, ventilationto the radiator 6 is blocked by the grille shutter 7 illustrated in FIG.1, so that a thermal insulating property on the radiator side of theengine 2 is increased, which is advantageous in introducing the hightemperature air into the combustion chamber.

Note that the invention according to introduction of air into an enginecombustion chamber is a technique useful for suppressing a decrease intemperature of the combustion chamber and is applicable not only to alean combustion mode but also to a combustion mode in the vicinity of aso-called theoretical air-fuel ratio.

Furthermore, although the whole of an opening of the inside air inlet 45of the embodiment faces the inside of the heat storage cover 21 from thebottom, a part of the opening may protrude outside the heat storagecover 21. The temperature of air becomes high in the vicinity of theheat storage cover 21 due to influence of the heat storage cover 21, sothat, even in a case where a part of the inside air inlet 45 protrudesoutside the heat storage cover 21 and air outside the heat storage cover21 is partially brought into the intake duct 11, the high temperatureair can be introduced into the engine combustion chamber.

(Layout of Intake Duct and the like)

According to the embodiment, as illustrated in FIG. 2, in the frontintake and rear exhaust engine 2, the inside air inlet 45 is disposed onthe front side of the engine 2, so that the inside air introductionpassage 56 from the inside air inlet 45 to the air cleaner 12 does notbecome long, which is advantageous in introducing the high temperatureair into the combustion chamber and also facilitates the layout of theintake duct 11.

As illustrated in FIGS. 6 to 8, the intake duct 11 is continuous to theside edge on the front side of the right-side face cover portion 24, sothat the intake duct 11 approaches the engine 2 as compared with a casewhere the intake duct 11 is disposed outside the side face cover portion24. This prevents an increase in a space occupied by, in the engine room2, the heat storage cover 21 and air intake system components includingthe intake duct 11, facilitating the layouts of the heat storage cover21 and the air intake system components in the engine room 2.

Furthermore, the intake duct 11 has a function of covering the engine 2from the right side, so that the right-side face cover portion 24 can bemade small accordingly. Similarly, regarding the left-side face coverportion 25, the engine mount 38 has a function of covering the engine 2from the left side, so that the left-side face cover portion 25 can bemade small accordingly.

By the shortening of the inside air introduction passage 56 and thedownsizing of the side face cover portions 24 and 25, which aredescribed above, the device is advantageously reduced in weight.

The intake duct 11 and the right-side face cover portion 24 are coupledtogether by the clip 35 (fastening member), so that the coupling isfacilitated and the intake duct 11 can be used for support of theright-side face cover portion 24, which is advantageous in reducing thenumber of components and enhancing mounting stability of the right-sideface cover portion 24.

As illustrated in FIG. 9 and the like, the inside air inlet 45 of theintake duct 11 is open upward, so that foreign matter entering theengine room 1 from the horizontal direction or the lower side is lesslikely to enter the inside air inlet 45, preventing damage to thepassage switching mechanism including the second valve 62 of the intakeduct 11. In particular, in the embodiment, as illustrated in FIG. 2, theinside air inlet 45 is covered with the heat storage cover 21 from thetop, so that it is advantageous in terms of entry of foreign matter.

On the other hand, while the inside air inlet 45 of the inside airintroduction duct portion 42 is open upward, as illustrated in FIGS. 11and 12, the duct wall 41 a of the outside air introduction duct portion41 is across above the inside air inlet 45, and in addition, theprojection portion 51 bulges above the inside air inlet 45. That is, theupper side of the inside air inlet 45 is covered not only with the ductwall 41 a of the outside air intake duct portion 41 but also with theprojection portion 45. Accordingly, if the heat storage cover 21 isremoved in maintenance or the like, foreign matter such as a bolt isblocked by the duct wall 41 a of the outside air introduction ductportion 41 and the projection portion 51 and thus is prevented fromentering the inside air inlet 45.

Furthermore, the passage switching mechanism composed of the valves 61and 62 and the like is provided inside the intake duct 11. The passageswitching mechanism, in particular, the second valve 62, might bedamaged by foreign matter entering the inside of the intake duct 11 fromthe inside air inlet 45. Accordingly, the upper side of the inside airinlet 45 is covered with the outside air introduction duct portion 41 soas to prevent entry of foreign matter into the inside air inlet 45,thereby preventing damage to the passage switching mechanism inside theintake duct 11 (in particular, the second valve 62) due to entry offoreign matter into the inside of the intake duct 11.

(Passage Switching Mechanism)

While the intake duct 11 is formed by welding of the first duct member11A and the second duct member 11B, as illustrated in FIG. 13, astructure is adopted in which the shaft support portions 65 and 66supporting the rotation shaft 63 of the passage switching mechanism, andthe actuator support portion 67 supporting the actuator 64 are providedin the second duct member 11B and in which this rotation shaft 63 andthis actuator 64 are supported by the second duct member 11B alone.Accordingly, if, due to welding of both duct members 11A and 11B, somedeformation occurs in the mating portion, its influence on the supportof the rotation shaft 63 and the actuator 64 is small. This prevents theoccurrence of a malfunction of the passage switching mechanism.

As illustrated in FIGS. 15 to 17, when the fitting portion 74 of thefirst valve 61 and the fitting portion 75 of the second valve 62 whichform the passage switching mechanism are engaged at their engagementportions 78 and 79, these both valves 61 and 62 are relativelypositioned in the valve rotation direction. This facilitates the anglesetting of both valves 61 and 62 in the valve rotation direction whenboth valves 61 and 62 are assembled to the rotation shaft 63.

Furthermore, the relative position between both valves 61 and 62 in thevalve axis direction is regulated by engagement of the projections 82and 83 provided in the fitting portions 74 and 75 of both valves 61 and62 with the spacer 81. Accordingly, the positions of both valves 61 and62 in the respective valve disposition portions in the valve axisdirection can be regulated only by, as described above, mounting thespacer 81 on the second duct member 11B in a state in which both valves61 and 62 are engaged at the engagement portions 78 and 79.

As described above, according to the embodiment, by the simpleconfiguration in which the engagement portions 78 and 79 and theprojections 82 and 83 are provided in the fitting portions 74 and 75 ofboth valves 61 and 62 and in which the spacer 81 to be mounted on thesecond duct member 11B is provided, it is advantageous in assemblingboth valves 61 and 62 to the respective valve disposition portions withhigh accuracy, and it is advantageous in preventing malfunctions of thevalves 61 and 62.

REFERENCE CHARACTERS LIST

1 engine room

2 engine

3 bonnet

4 cylinder block

5 oil pan

6 radiator

7 grille shutter

8 radiator fan

11 intake duct

11A first duct member

11B second duct member

12 air cleaner

21 heat storage cover

22 top face cover portion

23 rear face cover portion

24 right-side face cover portion

25 left-side face cover portion

35 clip (fastening member)

41 outside air introduction duct portion

41 a duct wall

42 inside air introduction duct portion

43 downstream duct portion

44 outside air inlet

45 inside air inlet

51 projection portion

55 outside air introduction passage

56 inside air introduction passage

57 downstream introduction passage

61 first valve

62 second valve

63 rotation shaft

64 actuator

73 to 77 fitting portion

78, 79 engagement portion

81 spacer

1. An air intake device for an engine, comprising: a cover providedinside an engine room and covering the engine; and an intake duct forintroducing fresh air outside the engine room into a combustion chamberof the engine, wherein the cover comprises a top face cover portioncovering the engine from above, and a side face cover portion coveringthe engine from a lateral side, and the intake duct is disposed so as tobe continuous to a side edge of the side face cover portion such thatthe intake duct covers the engine from the lateral side together withthe side face cover portion.
 2. The air intake device for an engineaccording to claim 1, wherein the engine room is provided in a frontportion of a vehicle, the engine is a front intake and rear exhaustengine, and the intake duct is disposed so as to be continuous to a sideedge on a front side of the side face cover portion.
 3. The air intakedevice for an engine according to claim 2, wherein the intake duct andthe side face cover portion are coupled together by a fastening member.4. The air intake device for an engine according to claim 3, wherein thefastening member is a clip having a retainer.
 5. The air intake devicefor an engine according to claim 1, wherein the intake duct comprises anoutside air introduction duct portion for introducing outside air whichis air outside the engine room into the combustion chamber, and aninside air introduction duct portion for introducing inside air which isair inside the engine room into the combustion chamber, and is acomposite duct in which the outside air introduction duct portion andthe inside air introduction duct portion are connected to one downstreamduct portion, the downstream duct portion having a downstream endconnected to an air cleaner, the engine room is provided in a frontportion of a vehicle, the air cleaner is disposed on a right outer sideof the cover as viewed from a vehicle front side, and the intake duct isdisposed on an outside of the cover and on a front side of the aircleaner, and covers the engine from a right side.
 6. The air intakedevice for an engine according to claim 5, wherein the outside airintroduction duct portion has an upstream end that is provided with anoutside air inlet open forward and having a horizontally longrectangular shape, the inside air introduction duct portion has anupstream end that is provided with an inside air inlet open upward andhaving a horizontally long rectangular shape, and the downstream ductportion has a downstream end having a connection port open rearward andconnected to the air cleaner.
 7. The air intake device for an engineaccording to claim 5, wherein the outside air introduction duct portion,at a higher position than the inside air inlet of the inside airintroduction duct portion, has a duct wall curved toward the inside airintroduction duct portion side and extending forward diagonally acrossabove the inside air inlet.
 8. The air intake device for an engineaccording to claim 4, wherein the side face cover portion comprises aright-side face cover portion covering the engine from a right side, theintake duct comprises a protrusion protruding rearward and extending inan up-down direction, the right-side face cover portion comprises amounting piece protruding forward relative to an upper end of a frontend edge of the right-side face cover portion, and the mounting piece isfixed to an upper end of the protrusion of the intake duct by a cliphaving a retaining function as a fastening member.